Multiple Composition Component Manufacturing via Hot Isostatic Pressing
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Solution Overview
Problem
Existing methods for manufacturing multiple composition components, such as turbine disks, face issues like structural weaknesses, impurity contamination, and residual stresses due to compositional differences and phase changes during processing, particularly in gas turbine engines where non-uniform conditions are encountered.
Innovation Solution
A method involving the arrangement of first, second, and third constituent parts with specific compositions, processed through hot isostatic pressing and/or diffusion bonding, where the second composition is compatible with the first and third, minimizing interface weaknesses and stresses by using a two-stage hot isostatic pressing process and optimizing gamma prime phase fractions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a slip case is used to separate first and second powders during manufacturing, then the powders can be kept separate during processing, but the slip case must be removed in a clean environment to prevent impurity contamination, which is difficult to achieve
Solution Approach 1:
The slip case is completely removed from the final component, extracting the separation function during processing while eliminating the contamination risk associated with leaving it in place. The powders are separated by the slip case during manufacturing, then the slip case is entirely extracted and removed, leaving only the desired constituent parts in the final component.
Solution Approach 2:
The slip case acts as an intermediary tool during the manufacturing process to maintain separation between different powder compositions. It facilitates the separation function temporarily during processing, then is removed entirely, avoiding the need for clean environment removal while ensuring proper separation of constituent parts.
2Productivity
If the slip case is removed, then the first and second powders can be processed to form a single component, but the powders mix together over a small transition region creating structural weaknesses
Solution Approach 1:
Different regions of the component are assigned different compositions to match local operational requirements. The first and second constituent parts have different compositions optimized for their respective regions, with the interface region having a transition composition that provides both structural integrity and functional optimization for each zone.
Solution Approach 2:
The final component is a composite structure with multiple constituent parts of different compositions. The interface region is designed as a transition zone with intermediate composition, creating a composite structure that maintains structural integrity while allowing the benefits of multiple different materials throughout the component.
3Adaptability or versatility
If multiple constituent parts with different compositions are combined, then the component can perform under non-uniform conditions, but new phases and carbides may be formed at the interface during manufacturing or heat treatment
Solution Approach 1:
The interface region is designed with a transition composition that is locally optimized to prevent harmful phase formation. This local compositional gradient ensures that the interface area has properties suitable for maintaining structural integrity while avoiding the formation of harmful phases that would compromise the component's ability to perform under non-uniform conditions.
4Adaptability or versatility
If constituent parts with significantly different compositions are used, then the component can be optimized for specific regions, but residual stresses may be formed at the interface between the different compositions
Solution Approach 1:
The transition region at the interface has a composition that is locally optimized to minimize compositional gradients. This intermediate composition reduces the abrupt changes in material properties, thereby minimizing residual stresses while still allowing different constituent parts to be optimized for their respective regions.
Solution Approach 2:
The composition parameters in the transition region are specifically controlled to minimize differences between adjacent constituent parts. By adjusting the compositional parameters in the interface region, the patent reduces thermal and mechanical property gradients that would otherwise generate residual stresses, while maintaining the benefits of regional optimization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the structural integrity and mechanical properties of multiple composition components by reducing residual stresses and phase formation at interfaces, allowing for optimized performance under non-uniform conditions without the need for a slip case removal, thus improving the manufacturing efficiency and component reliability.
Implementation Method 1
the processing including hot isostatic pressing and/or diffusion bonding, the hot isostatic pressing and/or diffusion bonding comprising hot isostatic pressing at a first temperature for a first predetermined time and hot isostatic pressing at a second temperature for a second predetermined time
Implementation Method 2
the processing including hot isostatic pressing and/or diffusion bonding
Data Source
AI summary
The present invention relates to a method of manufacturing a multiple composition component 10, comprising: arranging first, second and third constituent parts 40, 30, 42 having first, second and third compositions respectively A, B, C so that the first constituent part 40 shares a first boundary with the second constituent part 30 and the second constituent part 30 shares a second boundary with the third constituent part 40. The first, second and third constituent parts 40, 30, 42 are each either a powder or a solid so that the first and second boundaries are each a solid adjacent to a powder. The arrangement is then processed so as to form a single solid component having first, second and third regions 16, 18, 20 having first, second and third compositions A, B, C respectively.